Modular vertical lift system

ABSTRACT

A lift structure of a rack storage system including a pair of vertical post, a pair of guide rail portions stacked one on top of the other, a mounting brace, and a mounting platform attached to the pair of vertical post. The mounting brace includes an adjustment mechanism to adjust an alignment between the pair of guide rail portions fastened together by a clamping plate. A load handling station is secured to the mounting platform to support loads transported to and from the rack storage system, wherein the load handling station is located by locating a position of the mounting platform.

TECHNOLOGICAL FIELD

Example embodiments of the present disclosure relate generally to astorage and retrieval system and, more particularly, to a vertical liftsystem used in a storage and retrieval system.

BACKGROUND

Picking loads in warehouse or distribution centers for order fulfillmentcan be been challenging. Different transportation systems pick loadsfrom a source and transport them to a destination. The transportationsystems may be, for example, conveying devices or transport devices.Generally, warehouses or distribution centers for storing loads mayinclude a storage system that comprise a series of storage racks thatare accessible by the transport devices such as, but not limited to,shuttles or vertical lifts or stacker cranes that are movable withinaisles along the storage racks. These transport devices may be used forstoring and retrieving of loads in or from a storage rack of the storagesystem. Generally, the transport devices are comprised of multiplecomponents which may be positioned on a frame and outside the frame ofthe transport devices which works in synergy to control movement of thetransport devices and the movement of the loads handled by the transportdevices.

SUMMARY

The following presents a simplified summary to provide a basicunderstanding of some aspects of the disclosed material handling system.This summary is not an extensive overview and is intended to neitheridentify key or critical elements nor delineate the scope of suchelements. Its purpose is to present some concepts of the describedfeatures in a simplified form as a prelude to the more detaileddescription that is presented later.

Various example embodiments described herein relate to a rack storagesystem including a plurality of storage levels, a load handling stationprovided on each storage level and a vertical lift mounted on a liftstructure to transport loads to and from the load handling station. Thelift structure includes a guide rail facilitates movement of thevertical lift between the storage levels and a pair of vertical postspositioned adjacent to the guide rail. The lift structure furtherincludes a mounting platform attached in between the pair of verticalposts, wherein the loading handling station is secured to the mountingplatform such that the vertical lift aligns with the load handlingstation by locating a position of the mounting platform on the liftstructure while the vertical lift moves on the guide rail.

Various example embodiments described herein relate to a rack storagesystem, wherein the mounting platform is positioned orthogonally to theguide rail at predefined heights throughout a length of the verticalposts.

Various example embodiments described herein relate to a rack storagesystem, wherein the load handling station is a conveyor.

Various example embodiments described herein relate to a rack storagesystem, wherein the lift structure further includes: a power railreleasably attached to the guide rail to supply power to the verticallift while moving on the guide rail.

Various example embodiments described herein relate to a rack storagesystem, wherein the load handling station includes at least one sensorto locate a position of the load handling station.

Various example embodiments described herein relate to a lift structureof a rack storage system including a pair of guide rails, a first pairof vertical posts, and a second pair of vertical posts positioned inparallel to the first pair of vertical posts. The pair of guide rails ispositioned in between the first pair of vertical posts and the secondpair of vertical posts. A mounting platform attached to one of the firstpair of vertical posts or the second pair of vertical posts, wherein aload handling station is secured to the mounting platform to supportloads transported to and from the rack storage system.

Various example embodiments described herein relate to a lift structurefurther includes a plurality of mounting platforms attached to one ofthe first pair of vertical posts or the second pair of vertical posts tosupport load handling stations at multiple storage levels of the rackstorage system, wherein each mounting platform is installed at apredefined position throughout a length of the vertical posts.

Various example embodiments described herein relate to a lift structure,wherein the load handling station at each storage level is located usingthe predefined position of each mounting platform.

Various example embodiments described herein relate to a lift structure,wherein the pair of guide rails facilitates movement of the verticallift between the storage levels.

Various example embodiments described herein relate to a lift structure,wherein the mounting platform includes one or more fastening points toalign and fasten the load handling station to the mounting platform.

Various example embodiments described herein relate to a lift structure,wherein the load handling station includes at least one sensor to locatea position of the load handling station.

Various example embodiments described herein relate to a lift structure,wherein the pair of guide rails includes a first guide rail positionedin between the first pair of vertical posts and a second guide railpositioned in between the second pair of vertical posts.

Various example embodiments described herein relate to a lift structureincluding a clamping plate, a pair of guide rail portions stacked one ontop of the other, and a mounting brace attached to a vertical post andthe guide rail portions. The mounting brace includes an adjustmentmechanism to adjust an alignment between the pair of guide rail portionsfastened together by the clamping plate.

Various example embodiments described herein relate to a lift structure,wherein the guide rail portions are positioned parallel to the verticalpost and perpendicular to the mounting brace.

Various example embodiments described herein relate to a lift structure,wherein the adjustment mechanism further includes alignment bracketsslidably coupled with each other using one or more fasteners.

Various example embodiments described herein relate to a lift structure,wherein the alignment brackets are slidable laterally along one or moreaxes to adjust the alignment between the pair of guide rail portions.

Various example embodiments described herein relate to a lift structure,wherein the one or more fasteners comprise one of clamping bolts andnuts, jacking bolts and nuts or their combination.

Various example embodiments described herein relate to a lift structure,wherein multiple pairs of guide rail portions are stacked on top of eachother to form a guide rail.

Various example embodiments described herein relate to a lift structure,wherein a vertical lift is guided over the guide rail.

Various example embodiments described herein relate to a lift structure,wherein the mounting brace is positioned along a length of the verticalpost in between alternate pairs of guide rail portions.

The above summary is provided merely for purposes of summarizing someexample embodiments to provide a basic understanding of some aspects ofthe disclosure. Accordingly, it will be appreciated that theabove-described embodiments are merely examples and should not beconstrued to narrow the scope or spirit of the disclosure in any way. Itwill be appreciated that the scope of the disclosure encompasses manypotential embodiments in addition to those here summarized, some ofwhich will be further described below.

BRIEF DESCRIPTION OF THE DRAWINGS

The description of the illustrative embodiments can be read inconjunction with the accompanying figures. It will be appreciated thatfor simplicity and clarity of illustration, elements illustrated in thefigures have not necessarily been drawn to scale. For example, thedimensions of some of the elements are exaggerated relative to otherelements. Embodiments incorporating teachings of the present disclosureare shown and described with respect to the figures presented herein, inwhich:

FIG. 1 discloses a perspective view of a dual conveyor carriage on avertical lift structure, in accordance with an embodiment of the presentinvention.

FIG. 2 discloses a sectional view of the vertical lift structure of FIG.1 , in accordance with an embodiment of the present invention.

FIG. 3 discloses a perspective view of an attachment mechanism of amounting brace of FIG. 2 , in accordance with an embodiment of thepresent invention.

FIG. 4 discloses a perspective view of a rack storage system in whichthe vertical lift structure of FIG. 1 is installed, in accordance withan embodiment of the present invention.

FIG. 5 discloses a sectional view of one load handling station installedin the rack storage system of FIG. 4 , in accordance with an embodimentof the present invention.

DETAILED DESCRIPTION

Some embodiments of the present invention will now be described morefully hereinafter with reference to the accompanying drawings, in whichsome, but not all embodiments of the inventions are shown. Indeed, thedisclosure may be embodied in many different forms and should not beconstrued as limited to the embodiments set forth herein; rather, theseembodiments are provided so that this disclosure will satisfy applicablelegal requirements. The terms “or” and “optionally” are used herein inboth the alternative and conjunctive sense, unless otherwise indicated.The terms “illustrative” and “exemplary” are used to be examples with noindication of quality level. Like numbers refer to like elementsthroughout.

The components illustrated in the figures represent components that mayor may not be present in various embodiments of the invention describedherein such that embodiments may include fewer or more components thanthose shown in the figures while not departing from the scope of theinvention.

Turning now to the drawings, the detailed description set forth below inconnection with the appended drawings is intended as a description ofvarious configurations and is not intended to represent the onlyconfigurations in which the concepts described herein may be practiced.The detailed description includes specific details for the purpose ofproviding a thorough understanding of various concepts with likenumerals denote like components throughout the several views. However,it will be apparent to those skilled in the art that these concepts maybe practiced without these specific details.

As used herein, the terms “pick-up” or “store” or “deposit” or“retrieve” may collectively refer to various operations performed by thevertical lifts and the autonomous vehicle in the rack storage system.Thus, use of any such terms should not be taken to limit the spirit andscope of embodiments of the present disclosure.

As used herein, the term “load handling station” may be used to refer toa pick-up and deposit (P&D) conveyor or infeed/outfeed conveyor orbuffer conveyor which can support and convey loads using one or moreconveying elements. Thus, use of any such terms should not be taken tolimit the spirit and scope of embodiments of the present disclosure.

As used herein, the terms “guide track” or “guide rail” or “guide rail”may be used to refer to guideways or pathways through which the verticallifts and the autonomous vehicle are guided to store and retrieve theloads. Thus, use of any such terms should not be taken to limit thespirit and scope of embodiments of the present disclosure.

As used herein, the terms “storage system”, “retrieval system”, “rackstorage system”, “automated storage and retrieval system” may be used torefer to any portion of a warehouse or a distribution center havingmultiple storage racks with a provision to store and retrieve one ormore loads. Thus, use of any such terms should not be taken to limit thespirit and scope of embodiments of the present disclosure.

As used herein, the terms “plates”, “braces”, “brackets”, “mounts”,“side guide”, “flanges”, “side rail”, “beading” may be used to refer tostructural elements with provisions to mechanically couple with otherstructural elements of a mechanical system or an electrical system.

As used herein, the terms “loads” or “load” may be used to refer toitems, products, articles, packages, baggage, luggage, storagecontainers such as trays, totes, cartons, boxes, or pallets. Thus, useof any such terms should not be taken to limit the spirit and scope ofembodiments of the present disclosure.

Generally, a storage and retrieval system may be provided as atwo-dimensional or three-dimensional storage and retrieval system. Suchstorage and retrieval system are often referred to as Automated Storageand Retrieval System (ASRS or AS/RS). In such automated storage andretrieval system, throughput is always a concern due to increase instorage and retrieval times. Further, retrieving loads from the storageracks in a quick and efficient manner has been a constraint in most ofthe automated storage and retrieval system. Typically, the transportdevices may be movable in vertical directions and horizontal directionswithin the aisles which is defined between two adjacent storage racksfor storing and retrieving the loads. Each storage rack may be of apredefined height configured with multiple storage levels withpredefined depth to store the loads picked up by the transport devices.One such transport device which can move vertically at different heightsbetween the multiple storage levels is a vertical lift.

In some examples, the loads transported to/from the storage levels arecontained in storage containers such as trays, totes, cartons, boxes oron pallets. Depending on a storage capacity of the storage racks, theracks may be known as high density racks or ultra-high-density racks.Such storage containers are stored in the storage racks and retrievedfrom the storage racks using the vertical lift for performing operationssuch as, for example, order fulfilment or replenishment or buildingmixed pallets. While vertical lifts of various configurations have beenproposed to store and retrieve the loads or storage containers forfulfilling such operations in a warehouse or a distribution center, theprior known configurations of the vertical lifts have certain drawbacksduring installation and maintenance of the vertical lifts. Some of theconsiderations while designing the configurations of the vertical liftsto overcome the prior drawbacks are: minimize the storage and retrievaltime; maximize safety in handling loads during storage and retrieval byminimizing slippage, misalignment and jam, minimize wear and tear ofcomponents of the vertical lifts by modifying theconfiguration/arrangement to handle overload, stress, vibrations,derailing and other external factors affecting the lifespan and safetyof the vertical lifts and its components, modular vertical liftstructure, reduce labor for installation/maintenance with easy to mountcomponents on the vertical lift structure.

Through applied effort, ingenuity, and innovation, many of the aboveidentified problems have been solved by developing solutions that areincluded in embodiments of the present disclosure, many examples ofwhich are described in detail herein. The present disclosure relates toa vertical lift mounted on a lift structure which includes a mountingplatform. A load handling station is secured to the mounting platform tosupport loads transported to and from vertical lift. The vertical liftaligns with the load handling station by locating a position of themounting platform on the lift structure. Such a configuration may enableboth the vertical lift and the load handling station to be supported ona common lift structure ensuring minimal effort during installation ofthe lift structure in a rack storage system. According to an embodiment,the lift structure includes a mounting brace with an adjustmentmechanism to adjust an alignment between guide rail portions mounted onthe lift structure on which the vertical lift is guided. The adjustmentmechanism may ensure proper error free installation and alignment of theguide rail portions on the lift structure. According to an embodiment,the mounting brace and the mounting platform may be attached to verticalmasts of the lift structure.

According to an embodiment, the mounting platform is positionedperpendicular to the mounting brace when attached to the vertical masts.

According to an embodiment, the guide rail portions are positionedparallel to the vertical posts and perpendicular to the mounting brace.

According to an embodiment, the adjustment mechanism includes alignmentbrackets that are slidable laterally along one or more axes to adjustthe alignment between the pair of guide rail portions.

In the following detailed description of exemplary embodiments of thedisclosure, specific representative embodiments in which the disclosuremay be practiced are described in sufficient detail to enable thoseskilled in the art to practice the disclosed embodiments. For example,specific details such as specific method orders, structures, elements,and connections have been presented herein. However, it is to beunderstood that the specific details presented need not be utilized topractice embodiments of the present disclosure. It is also to beunderstood that other embodiments may be utilized and that logical,architectural, programmatic, mechanical, electrical and other changesmay be made without departing from the general scope of the disclosure.The following detailed description is, therefore, not to be taken in alimiting sense, and the scope of the present disclosure is defined bythe appended claims and equivalents thereof.

Throughout this specification, the terms ‘conveyors’ or ‘conveyordevices’ or ‘conveyor system’ may be used interchangeably and theseterms should be taken as an example of both roller conveyor, a beltconveyor, or their combination.

Throughout this specification, the terms ‘rollers’ or ‘conveyor rollers’may be used interchangeably and the term ‘belt’ or ‘conveyor belt’ maybe used interchangeably and should be taken as an example of a mediumwhich transports loads on the conveyor system.

Throughout this specification, the terms ‘lift structure’ or ‘verticallift structure’ may be used interchangeably and should be taken as anexample of a mechanical structure on which the vertical lift isinstalled.

Throughout this specification, the terms ‘storage and retrieval system’or ‘rack storage system’ may be used interchangeably and should be takenas an example of a system having storage racks.

Generally, storage and retrieval system operate under computerizedcontrol, maintaining an inventory of stored loads. Retrieval of loads isaccomplished by specifying the load type and quantity to be retrieved.The computer determines where in the storage area the load can beretrieved from and schedules the retrieval. The autonomous vehicles andthe vertical lifts are sometimes part of the storage and retrievalsystem. In some storage and retrieval system, the horizontal movement inthe storage racks within the system is made by independent shuttles eachoperating on one level of the storage rack while the vertical lift at afixed position within the storage rack is responsible for the verticalmovement. In some storage and retrieval system, the autonomous vehiclepicks up or drops off loads at specific load handling stations in thestorage area provided along with the storage rack. Inbound and outboundloads are precisely positioned for proper handling in the load handlingstations. Various aspects of the present disclosure are described inconnection with a lift structure used with the vertical lifts and theload handling stations of the storage and retrieval system.

Referring now specifically to the drawings and the illustrativeembodiments depicted therein, FIG. 1 discloses a perspective view of adual conveyor carriage on a vertical lift structure, in accordance withan embodiment of the present invention, in accordance with an embodimentof the present invention. The dual conveyor carriage 102 along with alifting unit 103 is mounted to the vertical lift structure 100 to formthe vertical lift. The dual conveyor carriage 102 and the lifting unit103 is guided on dual guide rails 106 a, 106 b, one rail 106 a installedin parallel with the other rail 106 b with two conveyor carriages 102positioned in between the rails. FIG. 1 includes two conveyor carriages102 independently movable on guide rails 106 a, 106 b to handle loadsstored in the storage racks of the storage and retrieval system,however, it is conceivable to use a single conveyor carriage on thevertical lift structure 100. According to an embodiment, a firstconveyor carriage 102 a and a second conveyor carriage 102 b on thevertical lift structure 100 may pick up and deposit the loads betweenthe load handling stations on the storage racks and outfeedstations/infeed stations. In some examples, the first conveyor carriage102 a may be employed to pick and deposit the loads at load handlingstations of a first set of storage levels and the second conveyorcarriage 102 b may be employed to pick and deposit the loads at loadhandling stations of a second set of storage levels. In some examples,both the first conveyor carriage 102 a and the second conveyor carriage102 b may be employed to pick and deposit the loads at the load handlingstations of any of the storage levels of the storage rack. In someexamples, the first conveyor carriage 102 a may pick the loads from theinfeed station and deposit the loads at a load handling station of aselected storage level and the second conveyor carriage 102 b may pickthe loads from the load handling station of the selected storage leveland deposit the loads at the outfeed station. In some examples, both thefirst conveyor carriage 102 a and the second conveyor carriage 102 b maysimultaneously pick and deposit the loads from or to the load handlingstation, the infeed station, and the outfeed station. In some examples,both the first conveyor carriage 102 a and the second conveyor carriage102 b may pick the loads from the infeed station and deposit the load ata common load handling station at a selected storage level withoutcollision between the first conveyor carriage 102 a and the secondconveyor carriage 102 b. Similarly, both the first conveyor carriage 102a and the second conveyor carriage 102 b may pick the loads from thecommon load handling station at the selected storage level and depositthe loads at the outfeed station without collision between the firstconveyor carriage 102 a and the second conveyor carriage 102 b. Suchconfigurations of the dual conveyor carriages 102 operating in thestorage and retrieval system to pick and deposit the loads without anycollision is disclosed in U.S. Pat. No. 10,611,568, incorporated hereinas a reference. A perspective view of a rack storage system with thestorage racks and the load handling stations is shown in FIG. 4 .

According to an embodiment, the first conveyor carriage 102 a and thesecond conveyor carriage 102 b are driven independently using drivingsystems. The driving systems may include drive belts 108, drive pulleys110 a, 110 b, and drive motors 112. The drive belts 108 are received forvertical rotation respectively on a pair of top drive pulleys 110 a andreceived independently on a pair of bottom drive pulleys 110 b, whereinthe bottom drive pulleys 110 b are driven by a pair of drive motors 112.The drive motors 112 independently rotate the bottom drive pulleys 110 bto independently control movement of the first conveyor carriage 102 aand the second conveyor carriage 102 b. According to an embodiment, asshown in FIG. 1 , the drive belts 108 are installed on the guide rails106 a, 106 b. In FIG. 1 , the drive belts 108 are installed on theparallel guide rails 106 a, 106 b, one drive belt on each guide rail 106a, 106 b. According to an embodiment, the drive belts 108 facilitate themovement of the first conveyor carriage 102 a and the second conveyorcarriage 102 b on the guide rails 106 a, 106 b under the influence ofthe drive motors 112. In some examples, the drive motors 112 include amotor encoder to track a position of the first conveyor carriage 102 aand the second conveyor carriage 102 b when guided on the guide rails106 a, 106 b. According to an embodiment, as shown in FIG. 1 , eachguide rail 106 a, 106 b is mounted to a pair of vertical mast 114. Forexample, a first guide rail 106 a may be positioned in between a firstpair of vertical mast 114 a and a second guide rail 106 b positioned inbetween a second pair of vertical mast 114 b. The first guide rail 106 aand the second guide rail 106 b mounted to the first pair of verticalmast 114 a and the second pair of vertical mast 114 b respectively usinga mounting brace 116. According to an embodiment, multiple mountingbraces 116 may be installed throughout a length of the vertical masts114 a, 114 b. A sectional view of one portion of the lift structure withmounting braces is shown in detail in FIG. 2 . According to anembodiment, the lift structure includes a mounting platform 130 attachedto the vertical masts 114 a, 114 b. The mounting platform 130 may bepositioned on the vertical masts 114 a, 114 b perpendicular to themounting brace 116. A sectional view of one portion of the liftstructure with mounting platforms is shown in detail in FIG. 2 .According to an embodiment, the mounting brace 116 and the mountingplatform 130 are fastened to the vertical masts 114 a, 114 b by usingsuitable fasteners secured within plurality of punctured holes 111provided throughout a length of the vertical masts 114 a, 114 b.

According to an embodiment, the first guide rail 106 a and the secondguide rail 106 b are mounted to a pair of top housings 118 and a bottomhousing 120 common for the first guide rail 106 a and the second guiderail 106 b. For example, one end of the first guide rail 106 a and thesecond guide rail 106 b may be attached to a first set of attachmentplates 121 on the pair of top housings 118 and other end of the firstguide rail 106 a and the second guide rail 106 b may be attached to asecond set of attachment plates 122 on the bottom housing 120, whereinthe attachment plates 121, 122 ensures proper alignment of the firstguide rail 106 a and the second guide rail 106 b. In some examples, thebottom housing 120 may include components such as the drive motors 112,bottom drive pulleys 110 b, bearings (not shown), and bottom spreader124. In some examples, the pair of top housings 118 may includecomponents such as the top drive pulleys 110 a, bearings (not shown),top spreader 123, and a pair of access plates 125 for maintenance of thecomponents inside the top housings 118. According to an embodiment, thefirst conveyor carriage 102 a and the second conveyor carriage 102 bpositioned in between the top housings 118 and the bottom housing 120are driven independently using the components inside the top housings118 and the bottom housing 120. According to an embodiment, the firstconveyor carriage 102 a and the second conveyor carriage 102 b may bepositioned in the vertical lift structure having a single common guiderail without any housings for the components as disclosed in U.S. Pub.No. 20200071074 incorporated herein for reference.

FIG. 2 discloses a sectional view of the vertical lift structure of FIG.1 , in accordance with an embodiment of the present invention. As shownin FIG. 2 , the mounting braces 116 are attached to the vertical posts114 a, 114 b and the guide rails 106 a, 106 b. For example, a firstmounting brace 116 a is positioned in between the first pair of verticalposts 114 a and a second mounting brace 116 b is positioned in betweenthe second pair of vertical posts 114 b. According to an embodiment,multiple first mounting braces 116 a and multiple second mounting braces116 b may be positioned throughout a length of the vertical posts 114 a,114 b at predefined intervals. According to an embodiment, the mountingbraces 116 a, 116 b are attached to the guide rails 106 a, 106 b.According to an embodiment, the guide rails 106 a, 106 b are attached tothe vertical posts 114 a, 114 b via the mounting braces 116 a, 116 b.According to an embodiment, the mounting braces 116 a, 116 b includeadjustment mechanism 202 to adjust an alignment between guide railportions of the guide rails 106 a, 106 b. For example, each guide rail106 a, 106 b are formed by multiple guide rail portions stacked one topof the other. According to an embodiment, the stacked guide railportions of each guide rail 106 a, 106 b are clamped together using aclamping plate 204. For example, a first clamping plate 204 a isprovided to clamp a second guide rail portion 201 a with a first guiderail portion 203 a stacked on top of the second guide rail portion 201a. The two guide rail portions 201 a, 203 a are attached to the firstpair of vertical mast 114 a through the mounting brace 116 a. On theother hand, a second clamping plate 204 b is provided to clamp a secondguide rail portion 201 b with a first guide rail portion 203 b stackedon top of the second guide rail portion 201 b. The two guide railportions 201 b, 203 b are attached to the first pair of vertical mast114 b through the mounting brace 116 b. Often, when the guide railportions 201 a, 201 b, 203 a, 203 b are stacked one top of the other toform the guide rails 106 a, 106 b, there might exist a possibility ofmisalignment between the guide rail portions 201 a, 201 b, 203 a, 203 b.Such misalignments are overcome by the adjustment mechanism 202 providedon each of the mounting braces 116 a, 116 b. As shown in FIG. 2 , theadjustment mechanism 202 of the mounting braces 116 a, 116 b areattached to the guide rails 106 a, 106 b at an attachment region belowthe clamping plates 204 a, 204 b, however, conceivable are otherarrangements in which the adjustment mechanism 202 may be attached tothe clamping plates 204 a, 204 b which in turn is attached to theattachment region of the guide rails 106 a, 106 b. According to anembodiment, the adjustment mechanism 202 on the mounting brace 116 maybe used for clamping and aligning the guide rail portions 201 a, 201 b,203 a, 203 b without a requirement of the clamping plate 204. Accordingto an embodiment, each guide rail 106 a, 106 b includes a power rail 207attached to an inner surface 209 of the guide rail 106 a, 106 b. Thepower rail 207 is used for providing power and communication to theconveyor carriages 102 a, 102 b when moving on the guide rails 106 a,106 b. For example, the power rail is mounted using mounting clamps 210on the inner surface 209 of the guide rails 106 a, 106 b. For example,the conveyor carriages 102 a, 102 b may include conductor shoes whichmay come in contact with the power rail 207 when moving on the guiderails 106 a, 106 b to provide the power and communication to theconveyor carriages 102 a, 102 b. According to an embodiment, theclamping plate 202 and the mounting brace 116 are attached an outersurface 212 of the guide rails 106 a, 106 b. According to an embodiment,the mounting brace 116 includes an outer surface 220 and an innersurface 219. The adjustment mechanism 202 is attached to the innersurface 219 and the outer surface 220 includes an opening 221 to accessthe adjustment mechanism 202. The mounting brace 116 and the adjustmentmechanism 202 are explained in detail in conjunction with FIG. 3 .

According to an embodiment, the mounting platform 130 is attached andpositioned in between one post of the first pair of vertical posts 114 aand one post of the second pair of vertical posts 114 b. The mountingplatform 130 may be positioned perpendicular to the guide rails 106 a,106 b and the mounting brace 116. According to an embodiment, themounting platform 130 is attached either to the first pair of verticalposts 114 a or the second pair of vertical posts 114 b. As shown in FIG.2 , a first mounting platform 211 and a second mounting platform 213 areattached to the vertical post 114 a, 114 b and positioned perpendicularto the mounting brace 116 a, 116 b. According to an embodiment, multiplemounting platforms may be installed throughout a length of the verticalposts 114 a, 114 b. The multiple mounting platforms may be positioned atpredefined positions throughout a length of the vertical posts 114 a,114 b. According to an embodiment, the load handling station is securedto each mounting platform 211, 213 to support loads transported to andfrom the rack storage system. According to an embodiment, each mountingplatform 211, 213 comprises one or more fastening points 215, 217 tosecure the load handling station. For example, the one or more fasteningpoints may be a pair of longitudinal openings 215, 217 to slidably alignand fasten the load handling station to the mounting platforms 211, 213.The use of mounting platforms 211, 213 on the vertical lift structure100 in conjunction with the load handling station is explained in detailin FIG. 5 .

FIG. 3 discloses a perspective view of the adjustment mechanism 202 ofthe mounting brace 116 of FIG. 2 , in accordance with an embodiment ofthe present invention. FIG. 3 shows a view of the inner surface 219 ofthe mounting brace 116 to which the adjustment mechanism 202 isattached. According to an embodiment, the mounting brace 116 may includea rectangular beading 301 provided on the inner surface 219 of themounting brace 116. In some example, the rectangular beading 301 may bea single molded piece attached to the inner surface 219 of the mountingbrace 116. In some examples, the rectangular beading 301 may be formedintegrally on the mounting brace 116 as a protrusion from the innersurface 219 of the mounting brace 116. In some examples, the rectangularbeading 301 may be formed by attaching two pairs of attachment plates303 to the inner surface 219 of the mounting brace 116. The two pair ofattachment plates 303 may be secured to each other using suitablefasteners or force/interference fits. When the two pairs of attachmentplates 303 are fastened to the inner surface 219 of the mounting brace116, one pair of attachment plates 303 a may be positioned perpendicularto the other pair of pair of attachment plates 303 b forming therectangular beading 301 on the inner surface 219. According to anembodiment, the rectangular beading 301 includes one or more apertures.For example, the one or more apertures may be provided on the two pairsof attachment plates 303 and positioned equidistant to each other. Forexample, a first set of apertures 305 a may be provided on one pair ofattachment plates 303 a and a second set of apertures 305 b may beprovided on other pair of attachment plates 303 b. According to anembodiment, the adjustment mechanism 202 may be positioned in betweenthe two pairs of attachment plates 303. According to an embodiment, thesecond set of apertures 305 b may be used for mounting the mountingbrace 116 to the vertical masts 114 a, 114 b. According to anembodiment, a third of apertures 305 c may be provided on the mountingbrace 116 for additional support for the mounting brace 116 on thevertical masts 114 a, 114 b. In some examples, the mounting brace 116may be attached to the vertical masts 114 a, 114 b using the second setof apertures 305 b and the third of apertures 305 c in combination withsuitable fasteners.

According to an embodiment, the adjustment mechanism 202 includesalignment brackets 302 that are slidable laterally along one or moreaxes to adjust the alignment between a pair of guide rail portions 201a, 201 b or 203 a, 203 b as shown in FIG. 2 . As shown in FIG. 3 , theadjustment mechanism 202 includes a pair of alignment brackets (i.e., afirst alignment bracket 302 a and a second alignment bracket 302 b).According to an embodiment, the alignment brackets 302 are slidablyattached to each other and with the rectangular beading 301. As shown inFIG. 3 , the first alignment bracket 302 a and the second alignmentbracket 302 b are slidably coupled to each other using mating grooves304 and suitable fasteners 306. A first pair of mating grooves 304 a maybe provided integrally on the first alignment bracket 302 a and a secondpair of mating grooves 304 b (not shown) may be provided integrally onthe second alignment bracket 302 b. In some examples, the first pair ofmating grooves 304 a and the second pair of mating grooves 304 b may beformed on opposing side surfaces 307 of the alignment brackets 302 a,302 b and may extend in the ‘Y’ axis substantially along a width of theopposing side surfaces 307. In some examples, the suitable fasteners 306may be jacking bolts, clamping bolts, screws, nuts, washers, or theircombination. The first pair of mating grooves 304 a may be coupled withthe second pair of mating grooves 304 b using the suitable fasteners 306such that the first alignment bracket 302 a may slide with respect tothe second alignment bracket 302 b. As shown in FIG. 3 , the firstalignment bracket 302 a and the second alignment bracket 302 b mayinclude a first flange 307 a and a second flange 307 b respectivelyextending from the opposing side surfaces 307 of the alignment brackets302 a, 302 b. The first flange 307 a and the second flange 307 bincludes integrally drilled holes (not shown) through which the suitablefasteners 306 are inserted to couple the flanges 307 a, 307 b together.In some examples, a third flange 307 c attached to the inner surface ofthe mounting brace 116 may be provided to couple with the second flange307 b through the drilled holes and the suitable fasteners 306. In someexamples, the first flange 307 a and the second flange 307 b are moldedintegrally on the opposing side surfaces 307 of the alignment brackets302 a, 302 b. In this manner, the first alignment bracket 302 a and thesecond alignment bracket 302 b are coupled to each other using themating grooves 304 and the suitable fasteners 306. According to anembodiment, the first alignment bracket 302 a includes additional groves313 provided on a front surface 308 of the bracket 302 a to enableattachment of the clamping plate 204 to the bracket 302 a. The opposingside surfaces 307 are at right angles to the front surface 308. Further,as shown in FIG. 3 , the second alignment bracket 302 b is slidablyattached with the rectangular beading 301. For example, the secondalignment bracket 302 b is slidably attached to the pair of attachmentplates 303 a through the first set of apertures 305 a. For example. thesecond alignment bracket 302 b may be fixed inside one or more aperturesof the first set of apertures 305 a with a clearance to slide the secondalignment bracket 302 b within the one or more openings. In someexamples, the second alignment bracket 302 b may be attached to the oneor more apertures of the first set of apertures 305 a in a mannersimilar to the attachment between the first alignment bracket 302 a andthe second alignment bracket 302 b using the mating groves 304 and thesuitable fasteners 306. In this manner, the first alignment bracket 302a and the second alignment bracket 302 b are slidably coupled to eachother and with the rectangular beading 301. The manner in which thealignment brackets 302 a, 302 b are fastened should be constructed asone example of enabling a slidable coupling between the alignmentbrackets 302 a, 302 b and the rectangular beading 301, therefore, maynot be construed as limiting the scope of the disclosure. Any alternatearrangement or use of any suitable fasteners for fastening the alignmentbrackets 302 a, 302 b and the rectangular beading 301 to achieve theobject of slidable coupling may be employed and may fall within thescope of the disclosure.

According to an embodiment, the alignment of the pair of guide railportions 201 a, 201 b or 203 a, 203 b in the ‘X’ axis and the ‘Y’ axismay be adjusted by a slidable movement of the alignment brackets 302. Inthe example, as shown in FIG. 3 , the slidable movement of the firstalignment bracket 302 a and the second alignment bracket 302 b isenabled using jacking bolts 310 a, 310 b. As discussed previously, thefirst alignment bracket 302 a, the second alignment bracket 302 b, therectangular beading 301 are slidable coupled to each other using themating grooves 304 a, 304 b, the first set of apertures 305 a, theflanges 307 a, 307 b, 307 c along with the suitable fasteners 306. Thejack bolts 310 a, 310 b are inserted through the flanges 307 a, 307 b,307 c and rotated in a clockwise or an anti-clockwise direction to slidethe first alignment bracket 302 a and the second alignment bracket 302 bin both the ‘X’ axis and the ‘Y’ axis. The sliding movement of the firstalignment bracket 302 a and the second alignment bracket 302 b in turnadjusts the alignment of the pair of guide rail portions 201 a, 201 b or203 a, 203 b in the ‘X’ axis and the ‘Y’ axis. According to anembodiment, at least one attachment bracket 302 a, 302 b may bedetachably attached to the pair of guide rail portions 201 a, 201 b or203 a, 203 b to adjust the alignment. In the example, as shown in FIG. 3, the first alignment bracket 302 a is attached to the pair of guiderail portions 201 a, 201 b or 203 a, 203 b using pairs of clips 312. Thepair of clips, for example, may be flexible or rigid. The pairs of clips312 may be clipped on to the guide rail portions 201 a, 201 b or 203 a,203 b to couple the alignment brackets 302 a, 302 b with the guide railportions 201 a, 201 b or 203 a, 203 b. The pairs of clips 312 may beprovided such that the installation of the mounting brace 116 with thepair of guide rail portions 201 a, 201 b or 203 a, 203 b is commissionedat ease with speedy attachment and detachment. According to anembodiment, the alignment of the pair of guide rail portions 201 a, 201b or 203 a, 203 b in the ‘Y’ axis is enabled by a first jack bolt 310 a.For example, the first jack bolt 310 a is inserted into the drilledholes of the flanges 307 a, 307 b and rotated in one of the clockwise orthe anti-clockwise direction to incrementally slide the first mountingbracket 302 a with respect to the second mounting bracket 302 b in the‘Y’ axis. The incremental sliding is enabled by the mating grooves 304a, 304 b positioned in an overlapping arrangement using the suitablefasteners 306, for example, clamping bolts and nuts. According to anembodiment, the alignment of the pair of guide rail portions 201 a, 201b or 203 a, 203 b in the ‘X’ axis is enabled by a second jack bolt 310b. For example, the second jack bolt 310 b is inserted into the drilledholes of the flanges 307 b, 307 c and rotated in one of the clockwise orthe anti-clockwise direction to incrementally slide the second mountingbracket 302 a with the first mounting bracket 302 a in the ‘X’ axiswithin the first set of apertures 305 a. It is to be noted that thefirst mounting bracket 302 a slides along with the second mountingbracket 302 b as these mounting brackets 302 a, 302 b are coupled witheach other. Therefore, when the second jack bolt 310 b is rotated, thesecond mounting bracket 302 b slides within the first set of apertures305 a on the rectangular beading 301 to enable the mounting bracket 302a, 302 b in the ‘X’ axis. According to an embodiment, the first jackbolt 310 a and the second jack bolt 310 b may be used in conjunctionwith locking nuts 311 to enable the jacks bolts 310 a, 310 b to belocked in position after the rotation in the clockwise or theanti-clockwise direction. In this manner, the jack bolts 310 a, 310 benable the sliding movement of the mounting brackets 302 a, 302 b whichin turn changes the alignment of the pair of guide rail portions 201 a,201 b or 203 a, 203 b. Therefore, the mounting brace adjusts thealignment between pairs of guide rail portions positioned distributedalong a length of the vertical masts while pairs of guide rail portionsare coupled using the clamping plates.

FIG. 4 discloses a perspective view of a rack storage system 400 inwhich the vertical lift structure 100 of FIG. 1 is installed, inaccordance with an embodiment of the present invention. The rack storagesystem 400 include multi-level storage racks 402, load handling stations404, a vertical lift 406 with a conveyor carriage 102, and an autonomousvehicle (not shown). According to an embodiment, multiple autonomousvehicles, each servicing storage racks 402 at one storage level orstorage racks 402 at multiple storage levels may be employed. Accordingto an embodiment, the vertical lift structure 100 including the verticallift 406 may be installed adjacent to the load handling stations 404. Insome examples, one load handling station 404 may be provided at eachstorage level which may be located adjacent the storage racks 402. Thevertical lift 406 may deposit a load 407 at a selected load handlingstation 404 of a selected storage level and the load 407 may then bepicked by the autonomous vehicle to store the load 407 at a selectedstorage rack 402. According to an embodiment, the autonomous vehicle maytravel laterally or vertically on guide tracks 502 as shown in FIG. 5within the rack storage system 400 to reach the selected storage rack402. According to an embodiment, the vertical lift 406 may retrieve theload 407 deposited by the autonomous vehicle at the load handlingstation 404. Therefore, the load handling stations 404 may handle loads407 which are to be stored in the storage racks 402 or retrieved fromthe storage racks 402. According to an embodiment, the load handlingstations 404 may include one or more conveying elements to support andtransfer the load 407 deposited or retrieved by the vertical lift 406 orthe autonomous vehicle. Often, the load handling stations 404 may beinstalled with the storage racks 402 of the rack storage system 400 andthe vertical lift 406 may be configured to calibrate with positions ofthe load handling stations 404 spread across the storage levels. Suchcalibration may be tedious with change in configurations or arrangementsof the rack storage system. According to an embodiment, the loadhandling stations 404 are installed on the mounting platforms 130, 211,213 provided with the vertical lift structure 100 of FIG. 1 . Suchmounting platforms 130, 211, 213 may be provided at known positions onthe vertical lift structure 100. The known positions of the mountingplatforms 130, 211, 213 allow the vertical lift 406 to align with theload handling stations 404. In other words, the vertical lift 406 may bepre-calibrated or pre-configured with the known positions of themounting platforms 130, 211, 213 which would remain constantirrespective of the configuration of the rack storage system.

FIG. 5 shows a sectional view of one of the load handling station 404installed on one of the mounting platforms 130, 211, 213 of the verticallift structure 100. In the FIG. 5 , the mounting platform 130 ispositioned in between either the first pair of vertical posts 114 a orthe second pair of vertical posts 114 b. According to an embodiment, themounting platform 130 may be positioned in between the guide tracks 502of the autonomous vehicle. In the FIG. 5 , two guide tracks 502 one oneach side of the mounting platform 130 is shown. The guide tracks 502are fastened to the pair of vertical posts 114 a. According to anembodiment, the load handling station 404 may be slidably coupled to themounting platform 130 using the one or more fastening points 215, 217.For example, the one or more fastening points 215, 217 may be a pair oflongitudinal openings 215, 217 as shown in FIG. 2 . Such longitudinalopenings 215, 217 are provided such that the load handling station 404may be aligned with an adjacent storage rack at a particular storagelevel. For example, the longitudinal openings 215, 217 may enable the‘Y’ axis sliding movement of the load handling station to align with theadjacent storage rack. According to an embodiment, the load handlingstation 404 may include one or more additional fastening points 515, 517for coupling with the mounting platform 130. For example, the one ormore additional fastening points 515, 517 may be a pair of additionalopenings 515, 517 (not shown) transverse to the longitudinal openings215, 217. For example, the pair of additional openings 515, 517 mayenable the ‘X’ axis sliding movement of the load handling station 404 toalign with the adjacent storage rack. According to an embodiment, thelongitudinal openings 215, 217 may mate with the additional openings515, 517 and coupled together using suitable fasteners known in the art.In this manner, the load handling station 404 may be slidably coupled tothe mounting platform 130 and accurately aligned with the adjacentstorage rack by sliding in both the ‘X’ axis and the ‘Y’ axis. Accordingto an embodiment, a position of the mounting platform 130 on thevertical masts 114 a may be known. For example, the mounting platform130 may be located at a predetermined distance with reference to a floorat which the vertical lift structure 100 may be installed. Thepredetermined distance may be pre-programmed in the vertical lift 406before operating the vertical lift 406 in the rack storage system 400.For example, the vertical lift 406 may consider the position of themounting platform 130 as a reference point for locating the loadhandling platform 404. According to an embodiment, multiple mountingplatforms 211, 213 may be attached to the vertical posts 114 a, 114 b tomount the load handling stations 404. In some examples, each mountingplatform 211, 213 may be positioned at predetermined distances relativeto the floor or at predetermined distances relative each other. Suchpredetermined distances may be pre-programmed in the vertical lift 406before operating the vertical lift 406 in the rack storage system 400.

According to an embodiment, the vertical lift 406 may be pre-calibratedbefore mounting the load handling station 404 to the mounting platform130. For example, the vertical lift may be guided on the vertical masts114 a, 114 b under the influence of the driving systems as discussed inFIG. 1 . The vertical lift 404 is then programmed to detect the mountingplatform 130 using one or more sensors. The one or more sensors, forexample, may be a diffused proximity sensor or a photoelectricretro-reflective sensor with a reflective surface on the mountingplatform 130. After the vertical lift 404 detects the mounting platform130, the position of the mounting platform 130 is recorded. In thismanner, the position of all the mounting platforms 130, 211, 213 mountedthroughout the length of the vertical masts 114 a, 114 b ispre-calibrated using the one or more sensors on the vertical lift 404.Such pre-calibration may be used for locating the position of each loadhandling platform 404 before operating the vertical lift 406 within therack storage system 400. According to an embodiment, the load handlingstation 404 may be located dynamically by the vertical lift 406 whileoperating in the rack storage system 400. For example, the vertical lift406 locates the load handling station 404 using a single sensor 504 whenthe vertical lift 406 travels on the guide rails 106 a, 106 b of thelift structure 100. The sensor 504, for example, may be a photoelectricthrough-beam sensor with transmitter of the sensor 504 located on theload handling station 404 and a receiver of the sensor 504 located onthe vertical lift 406. When the receiver on the vertical lift 406detects the light from the transmitter during the travel, the verticallift 406 may be stopped at that position considering it to be thelocation of the load handling station 404. Alternatively, thetransmitter of the sensor 504 may also be positioned on the mountingplatform 130 to locate the load handling station 404. Therefore, themounting platform may support the load handling station within thevertical lift structure and locate the load handling station wheninstalled with the rack storage system.

The distributed control architecture and control logic for controllingthe vertical lifts, the autonomous vehicle, and the load handlingstation are disclosed in FIGS. 6 and 7 of U.S. Pat. No. 10,611,568incorporated herein for reference.

The various illustrative logical blocks, modules, circuits, andalgorithm steps described in connection with the embodiments disclosedherein may be implemented as electronic hardware, computer software, orcombinations of both. To clearly illustrate this interchangeability ofhardware and software, various illustrative components, blocks, modules,circuits, and steps have been described above generally in terms oftheir functionality. Whether such functionality is implemented ashardware or software depends upon the particular application and designconstraints imposed on the overall system. Skilled artisans mayimplement the described functionality in varying ways for eachparticular application, but such implementation decisions should not beinterpreted as causing a departure from the scope of the presentinvention.

The foregoing description of an embodiment has been presented forpurposes of illustration and description. It is not intended to beexhaustive or to limit the invention to the precise form disclosed.Obvious modifications or variations are possible in light of the aboveteachings. The embodiment was chosen and described in order to bestillustrate the principles of the invention and its practical applicationto thereby enable one of ordinary skill in the art to best utilize theinvention in various embodiments and with various modifications as aresuited to the particular use contemplated. Although only a limitednumber of embodiments of the invention are explained in detail, it is tobe understood that the invention is not limited in its scope to thedetails of construction and arrangement of components set forth in thepreceding description or illustrated in the drawings. The invention iscapable of other embodiments and of being practiced or carried out invarious ways. Also, in describing the embodiment, specific terminologywas used for the sake of clarity. It is to be understood that eachspecific term includes all technical equivalents which operate in asimilar manner to accomplish a similar purpose.

1. A rack storage system comprising: a plurality of storage levels; aload handling station provided on each storage level; a vertical liftmounted on a lift structure to transport loads to and from the loadhandling station, wherein the lift structure comprises: a guide railfacilitates movement of the vertical lift between the storage levels; apair of vertical posts positioned adjacent to the guide rail; a mountingplatform attached in between the pair of vertical posts, wherein theloading handling station is secured to the mounting platform such thatthe vertical lift aligns with the load handling station by locating aposition of the mounting platform on the lift structure while thevertical lift moves on the guide rail.
 2. The rack storage system ofclaim 1, wherein the mounting platform is positioned orthogonally to theguide rail at predefined heights throughout a length of the verticalposts.
 3. The rack storage system of claim 1, wherein the load handlingstation is a conveyor.
 4. The rack storage system of claim 1, whereinthe lift structure further comprises: a power rail releasably attachedto the guide rail to supply power to the vertical lift while moving onthe guide rail.
 5. The rack storage system of claim 1, wherein the loadhandling station comprises at least one sensor to locate a position ofthe load handling station.
 6. A lift structure of a rack storage systemcomprising: a pair of guide rails; a first pair of vertical posts; asecond pair of vertical posts positioned in parallel to the first pairof vertical posts, wherein the pair of guide rails is positioned inbetween the first pair of vertical posts and the second pair of verticalposts; and a mounting platform attached to one of the first pair ofvertical posts or the second pair of vertical posts, wherein a loadhandling station is secured to the mounting platform to support loadstransported to and from the rack storage system.
 7. The lift structureof claim 6, further comprises: a plurality of mounting platformsattached to one of the first pair of vertical posts or the second pairof vertical posts to support load handling stations at multiple storagelevels of the rack storage system, wherein each mounting platform isinstalled at a predefined position throughout a length of the verticalposts.
 8. The lift structure of claim 7, wherein the load handlingstation at each storage level is located using the predefined positionof each mounting platform.
 9. The lift structure of claim 6, wherein thepair of guide rails facilitates movement of the vertical lift betweenthe storage levels.
 10. The lift structure of claim 6, wherein themounting platform comprises one or more fastening points to align andfasten the load handling station to the mounting platform.
 11. The liftstructure of claim 6, wherein the load handling station comprises atleast one sensor to locate a position of the load handling station. 12.The lift structure of claim 6, wherein the pair of guide rails comprisesa first guide rail positioned in between the first pair of verticalposts and a second guide rail positioned in between the second pair ofvertical posts.
 13. A lift structure of a rack storage systemcomprising: a clamping plate; a pair of guide rail portions stacked oneon top of the other; a mounting brace attached to a vertical post andthe guide rail portions, wherein the mounting brace comprises:adjustment mechanism to adjust an alignment between the pair of guiderail portions fastened together by the clamping plate.
 14. The liftstructure of claim 13, wherein the guide rail portions are positionedparallel to the vertical post and perpendicular to the mounting brace.15. The lift structure of claim 13, wherein the adjustment mechanismfurther comprises: alignment brackets slidably coupled with each otherusing one or more fasteners.
 16. The lift structure of claim 15, whereinthe alignment brackets are slidable laterally along one or more axes toadjust the alignment between the pair of guide rail portions.
 17. Thelift structure of claim 15, wherein the one or more fasteners compriseone of clamping bolts and nuts, jacking bolts and nuts or theircombination.
 18. The lift structure of claim 13, wherein multiple pairsof guide rail portions are stacked on top of each other to form a guiderail.
 19. The lift structure of claim 18, wherein a vertical lift isguided over the guide rail.
 20. The lift structure of claim 18, whereinthe mounting brace is positioned along a length of the vertical post inbetween alternate pairs of guide rail portions.